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AbstractGeneral trends in the development of industrial processes and catalysts for the dehydrogenation of
lower C3C5 paraffins and olefins are considered. A brief review of studies on the improvement of commercial
nickelcalcium phosphate and iron oxide catalysts for the dehydrogenation of olefins and ethylbenzene to
dienes and styrene, respectively, performed in the Laboratory of Dehydrogenation at the Boreskov Institute of
Catalysis (Siberian Division, Russian Academy of Sciences) in collaboration with OAO NPO Yarsintez is given.
The results of studies on the development of new spinel-supported bimetallic PtSn catalysts for the steam
dehydrogenation of lower paraffins are presented.
1
INTRODUCTION
Olefins and dienes (propylene, n-butenes, isobutylene, butadiene, isoprene, styrene, and its derivatives)
are in considerable current use in various chemical
industries for the production of synthetic rubbers, plastics, automotive fuel components (methyl tert-butyl
ether (MTBE), tert-amyl methyl ether, and alkylates),
and other valuable chemical products. For this reason,
there has been considerable interest worldwide in
intensifying their production within the last half a century. Catalytic dehydrogenation is one of the most
important among currently available methods. Therefore, the number of studies on the improvement of old
and the development of new dehydrogenation catalysts
remains high. The results of these studies were summarized in several reviews and monographs [13]. However, some of the reviews appeared more than 20 years
ago, and it seems reasonable to consider current trends
in this area and analyze the results concerning the
improvement and development of new domestic dehydrogenation catalysts and processes.
1. TRENDS IN THE DEVELOPMENT
OF DEHYDROGENATION METHODS
AND CATALYSTS
The processes of catalytic dehydrogenation of lower
paraffins, olefins, and alkylaromatic hydrocarbons have
the highest throughputs in the world chemical industry.
The development of dehydrogenation methods in Russia was different from that in Western countries at the
same time. With the exception of the 1990s, the years
of reforms,2 monomers for synthetic rubber were syn1 Proceedings
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1990
Consumption of MTBE
8.3
Consumption of isobutylene for
5.3
MTBE
Isobutylene sources:
catalytic cracking (FCC) 8.3
steam cracking (SC) 3.2
dehydration of tert-butanol 2.2
dehydrogenation of isobutane 1.1
Total
14.8
1995
2000
19.8
12.7
22.0
13.8
9.2
3.7
2.2
8.5
23.6
9.8
3.8
2.2
9.7
25.5
66
BUYANOV, PAKHOMOV
process failed.
nently be retained in the cycle. Another important problem is the disposal of spent catalysts and finely divided
phases formed in the process.
The above problems served to motivate UOP, which
used and licensed a process of this type since the 1940s,
to repudiate this process in the 1970s when this company started to advertise the new Oleflex process,
which is environmentally safer [5].
3. Oleflex process (UOP). This process for isobutane and propane dehydrogenation was first introduced
in Thailand in 1990 [5, 12]. The process was developed
on the basis of the following two successfully operating
UOP processes: the Pacol process for the dehydrogenation of paraffins from the kerosene fraction to monoolefins and the CCR platforming process for the reforming
of naphtha in the production of high-octane gasoline.
The Oleflex process is performed with a moving bed of
a bead platinum catalyst in a multiple-stage reactor unit
via a reactorregenerator circuit with intermediate heat
absorption between the steps. Three or four reactors are
required for ~40% conversion in the dehydrogenation
of isobutylene or propane, respectively.
This process is characterized by high capital outlays
because of sophisticated apparatus. Moreover, this
technology requires a high mechanical strength of the
catalyst. It is likely that, for the above reasons, the first
plant in Thailand was put into operation with a 10-year
delay in spite of booming publicity program.
4. Steam active reforming (STAR) process of Phillips Petroleum Co. This process is performed in the
fixed bed of a catalyst. The platinum catalyst supported
on spinel [13] is placed inside tubes heated by flue
gases. The process is characterized by sophisticated
apparatus. According to promotional materials of the
company, this process was scheduled for commercialization in as early as 1992. However, until recently,
there was no information on the industrial implementation of this process. Only the Oil and Gas Journal [14]
reported on the project of Polibutenos Argentinos S.A.,
according to which a plant for isobutylene dehydrogenation by the STAR process with the annual capacity
40000 ton was scheduled to be put in operation in 1994.
In this case, the catalyst was expected to operate in 7
8-h cycles with 1-h regeneration.
Table 2 summarizes the main characteristics of the
Catofin, Oleflex, STAR, and FBD processes. The information on plants that were in operation or projected in
the 1990s can be found in [15, 16].
A new single-stage process for the steam dehydrogenation of isopentane to isoprene at an atmospheric
pressure has no analogs in the world industry. This process and the IM-22101 catalyst were developed by the
Boreskov Institute of Catalysis in collaboration with
OAO NPO Yarsintez. Spinel-supported platinum modified with tin additives is used as a catalyst [8]. The process
is performed as short dehydrogenationregeneration
cycles in an adiabatic fixed-bed reactor. The per-pass yield
of isoprene is at least 14.5 wt % at 8284 wt % selectivity
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Table 2. Comparison of current industrial technologies for the dehydrogenation of lower paraffins
Process
Catofin
License holder
Operating mode
Reactor type
Total number of reactors
Duration of a dehydrogenation
regeneration cycle
Process conditions:
T, C
Pressure, atm
Diluent : hydrocarbon, mol/mol
Propylene production
propane conversion, %
selectivity for C3H6 , %
Isobutylene production
isobutane conversion, %
selectivity for iso-C4H8, %
Oleflex
United Catalysts/LumUOP
muss Crest
Cyclic
Moving bed
Adiabatic
Adiabatic
5
4
25 min
Continuous
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13
1*
482621
38
2**
65
87
40
90
3040
8090
6065
95
4550
9192
4555
8590
No. 1
2001
FBD
525677
0.10.7
0
STAR
520600
1.11.5
0
50
>90
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BUYANOV, PAKHOMOV
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Table 3. Performance characteristics of phosphate catalysts in the processes of butylene and isoamylene dehydrogenation
Catalyst
Feedstock
Catalytic characteristics*
X, %
S, wt %
Dow-B (USA)
Service life
Improved parameter
5000 h
Butylenes
38
89
KNF
4000 h
Butylenes
Isoamylenes
37
38
85
86
Butylenes
Isoamylenes
40
43
85
87
IM-2204
IM-2206
Longer than
two years
Butylenes
Isoamylenes
46
45
86
88
* X is the degree of conversion, and S is the selectivity for butadiene or isoprene, respectively.
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Conversion, %
Selectivity, mol %
30.4
85.1
35.5
39.6
44.2
49.0
78.9
80.1
76.5
78.5
2KFeO2 + CO2,
K2SiO3 + -Fe2O3
2KFeO2 SiO2 (solid solution).
The formation of potassium ferrite is significantly
favored on calcination in a steam atmosphere: the temperature of the onset of reaction decreases by 150200 K, and
the reaction proceeds to a higher degree.
In studies of the stability of the phase composition
of the catalyst in various media, it was found that pure
potassium ferrite undergoes reduction under the conditions of n-butene dehydrogenation at a molar H2O/C4H8
ratio lower than 15. The addition of silicon compounds
to the catalyst stabilizes the phase composition in the
reaction medium, and the KFeO2SiO2 solid solution is
not reduced even at H2O/C4H8 = 6. The yield of target
products increases when the feedstock is diluted with
steam. Moreover, steam is a heat-transfer agent, and the
catalyst exhibits self-regenerating properties in its presence. Therefore, the optimum dilution above the specified limit depends on the operational characteristics of
the process rather than on the physicochemical properties of the catalyst.
The properties of catalysts based on rubidium and
cesium ferrites were also examined, and a perfect analogy to the formation of the ironpotassium system was
found. However, Table 4 indicates that the catalytic
activity of the catalysts was dramatically improved
when potassium is replaced by rubidium or cesium.
Table 5. Performance characteristics of catalysts based on iron oxides and alkali metals in the processes of ethylbenzene and
olefin dehydrogenation
Catalyst
Catalytic characteristics*
X, %
S, wt %
K-22
K-24
6065
72
8788
8990
K-26
K-28
75
72
90
97
K-16u
K-24
K-28
2830
2224
3740
7580
82
9095
Service life,
years
Improved parameter
Ethylbenzene dehydrogenation
1.52
2
Changes in the chemical composition of catalysts for increasing
the concentration of an active componenta solid solution of silicon
and chromium in the crystal lattice of potassium ferrite
Changes in the activation conditions for the ingress of chromium into
the lattice of an active component
* X is the degree of conversion, and S is the selectivity for styrene or butadiene, respectively.
KINETICS AND CATALYSIS
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A catalyst of this type is used in the UOP Oleflex process [5, 12].
(2) Bimetallic catalysts supported on alumina
spinel.
In the catalysts of the second type, both the active
component and spinel are highly resistant to steam.
Therefore, it became possible to perform the dehydrogenation of paraffins in a steam atmosphere; the partial
pressure of hydrocarbons was thus reduced, and the
yield of target products was increased. Moreover, steam
can serve as a heat-transfer agent to provide the zone of
endothermic reaction with heat. It is well known that
both chromiaalumina catalysts and platinumalumina
catalysts cannot work in a steam atmosphere, because
steam poisons chromium oxide is poisoned and causes
alumina support agglomeration.
Considering the above facts, we focused our efforts
toward developing a new catalyst for the dehydrogenation of lower paraffins on a bimetallic platinum-containing system supported on spinel [8, 9]. However, we
worked on the catalyst for a new single-stage process,
which had no precedent at that time, rather than on the
catalyst for the STAR process [12, 14]. This new process was the steam dehydrogenation of isopentane to
isoprene (or n-butane to butadiene) at an atmospheric
pressure, which did not require sophisticated vacuum
equipment.
The situation that existed in the late 1970s before
our studies was paradoxical. Almost all conceivable
procedures for the preparation of bimetallic catalysts of
this type were patented, and all available elements of
the periodic table were recommended for use as modifying additives to supported platinum [2]. At the same
time, no theory of the design and preparation of such
catalysts was developed.
The physicochemical basis for the preparation of
new-generation bimetallic catalysts supported on thermally stable spinel for C3C5 paraffin dehydrogenation
was developed is due to studies performed in our laboratory. This made it possible to optimize the composition and working conditions of the catalyst and develop
a technology for its production.
Note that the development of a preparation procedure for these catalysts consisted in solving the following two relative problems.
(1) The development of a scientific basis for the synthesis of spinel support with the desired composition
and texture characteristics.
Table 6. Catalytic characteristics of supported and bulk catalysts based on alkali metal ferrites in the dehydrogenation reactions of olefins
Catalyst
T, C H2O/C4H8, mol/mol Conversion of n-butenes, % Yield of C4H6, mol % Selectivity, mol %
Supported catalyst 580
10
34.8
31.7
91.0
Bulk catalyst
600
10
33.6
29.8
88.6
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Selectivity,
mol %
100
Conversion, %
100
90
90
80
80
70
70
60
60
50
40
Divinyl yield, mol %
13
3
12
11
10
600
650
700
750
800
T, C
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BUYANOV, PAKHOMOV
Selectivity, mol %
100
Selectivity, mol %
100
2
(a)
1
2
3
90
80
80
Conversion, %
3
70
Conversion, %
60
2
(b)
2
40
1
(c)
3
1
1
2
3
Reaction time, h
1
0
(b)
60
50
Yield, mol %
2
()
2
3
Reaction time, h
Fig. 2. Effect of the feed dilution with steam on (a) the selectivity for isobutylene, (b) the conversion of isobutane, and
(c) the yield of butadiene in the dehydrogenation of isobutane on a PtSn/ZnAl2O4 catalyst. H2O/iso-C4H10 : (1) 0,
(2) 10, and (3) 20 (T = 575C; V iso-C H = 600 h1;
4
10
H2 : iso-C4H10 = 1 : 1).
10
Table 7. Effect of the nature of modifying additives on the catalytic properties of platinum in the reaction of isobutane dehydrogenation*
Dilution, mol/mol
Catalyst
PtSn/ZnAl2O4
PtIn/ZnAl2O4
1:1
1 : 10
H2
H2
H2
H2
H2O
H2O
Selectivity, mol %
Conversion, %
54.4
75.7
43.9
54.2
4.6
2.8
0.8
0.3
oxidation
(CO2 + CO)
3.4
4.3
3.4
3.5
0
1.8
0
1.4
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13.
14.
15.
16.
17.
18.
ACKNOWLEDGMENTS
This work was supported by OAO Nizhnekamskneftekhim and the Russian Foundation for Basic
Research (project no. 00-15-97440, Leading Scientific
Schools).
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20.
21.
22.
REFERENCES
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